Condensation product



Patented May 31, 192?.

,sases Fries.

may 0. r. wanna, or ancawoon rams,

PENNSYLVANIA, ASSIGNOB TO WESTING- nousa amc'rarc & manuracronms COMPANY, A coRPomu-nm F mmmm VANIA.

connnnsa'rron raonucr.

Io Drawing.

This invention relates to condensation products, more especially, to phenolic condensation products, being directed to the production of a material of this type which 5 will obviate many of the steps previously considered necessary in the making of suc condensation products. More particularly,

this invention relates to the preparation of a compositematerial including a carbohydrate,

such as cellulose, which may be built up into plates or other suitable forms by molding.

This invention has, among its objects, the utilization of ingredients ordinarily used in the making of finished or semi-finished condensation products, in conjunction with cellulose, by impregnatin or combiningcellulose with the initia ingredients, thus making the 'cellulose a part of the reacting system during the condensation.

Hitherto, in making a composite material, it was customaryto first produce the condensation product in soluble form, the cellulose or other material being then impregnated with the condensation product, either in the fused or in dissolved state, after which the impregnated material was treated under heat and pressure to harden the binder.

This procedure involved numerous steps,

among which was the production of the ini0 termediate condensation product by allowing formaldehyde or itsequivalent to react upon a phenolic substance under carefull controlled conditions in order that the resulting product might have suitable charac- 5 teristics for the impregnation of material such as cellulose, which was done at a later stage. Such control required expert attention and closely regulated conditions. 'Material impregnated with such a product was 0 not permeated thereby, but was simply covered with the material. This condition was 7 due largely to the viscosity of the condensation product which prevented dee penetration thereof into the cellulose, orming a 5 composite product which was not uniform throughout. 1

It has also been proposed to parchmentize or hydrolyze cellulose by means of a parchmentizing agent, such as zinc chloride, and,

after suitable treatment, to impre ate the material with a phenolic condensat1on rodnot. This modification has greater isadvantages since it is necessary to firstparchmentize the material and then thoroughly P wash it to remove all of the parchmentizing was then .lpplloatlqm filed September 24, 1820. Serial No. 412,588.

agent, after which the water remammg' in the fiber is eliminated by washing with alcohol or other organic solvent to remove the water and replace it with the alcohol or other solvent. The material thus treated placed 1n a solution of a phenolic condensation product to allow the product to permeate the material. The successive steps necessitated extra labor and consumed considerable time become effective. In the case of garchmentized fiber even this method can be at mperfect at best since the material to be impregnated is a colloid if properly parchmentized, and the condensation product is also largely a colloid. It is known, of course, that two such materials do not permeate each other. The roduct formed thereby is not materially different from that formed by the first named process 1n that the condensation product does not penetrate appreciably into the cells of the fibers used ut merely coats the surfaces thereof.

The present invention obviates all the difiicultles encountered in prior methods, producmg a composite material by the combination of the basic ingredients which make up the condensation product with the materlal to be impregnated. In order to accomphsh this, I generally-prefer to parchmentize a fiber, although this step is not, in all y cases, necessary. The parchmentizing agent is usua y allowed to remain in the fiber, after which the fiber is treated with either phenol or formaldehyde to form a compound with the cellulose of the fiber. The material so treated is then impregnated with formaldehyde or phenol, as the case may be, and Sub ected to heat and pressure to form the condensation product. Various modifications of this procedure may be made, some of which are described hereinbelow. 4 Many advantages result from proceeding 1n thevmanner indicated. By impregnating with the individual ingredients, or a mix ture of several ingredients of the final condensation product, deeper penetration of the fiber is obtained, as these constituents are much more mobile than the customary impregnating agents. For instance, phenol or formaldehyde is much less viscous than a phenolic condensation product or a varnish. I

Further, the presence of water does not in tertere w1th penetration. Since the base to be impregnated itself enters into combination with the impregnating substance, contact is much moreint mate and the resulting condensation reaction is much more diffuse,

' allowing better control thereof, avoiding any danger of the reaction'becoming violent, a difliculty whichwas very serious in prior methods. I eliminate the use of solvents and of an intermediate phenolic condensation product, thus lowering the cost of the material considerably. made continuous and labor and, particularly, avoids the tedious washing operations necessary when a rior rocess involving parchmentizatlon o the bar was used.

My new method preferably involves the formation of a reactive cellulose by means of parchmentization, the parchmentizing agent being combined with the cellulose and roviding a-catalyst for the succeeding conensation reaction. The treatment with either phenol or formaldehyde subsequent to the parchmentization or, in some'cases, simultaneously therewith, results in the formation of compounds wlth the cellulose, a

involves very little phenol ether probably being formed.- whenhenol is combined therewith, and a formalfiehyde addition product in the case of combination with formaldehyde. One procedure in practicing my invention consists in first pare mentizing or hydrolyzbe accomplished with the use of ordinary parchmentizing agents, such as zinc chloride or sulphuric acid, but I have found that the'use of caustic soda, or

' other alkali, or sodium zincate or similar material is preferable.

The latter substances are not only archmenti'zing agents but act as catalysts in the condensation reactloni These substances are. less sensitive to varia- 'tions in the conditions of the reaction and their use requires less careful control of the factors than does the use of the other parchmentizing a ents. When caustic soda is of the fiber takes place. I have found that such shrinkage can be controlled and practically entirelyprevented by the ad-', dition of a salt, such as 10 to 15% sodium chloride. Instead of sodium zincate,-I may use other salts,'such as stannates, 'stannites, antimonates, aluminates," titanates, and, in general, compounds of vamphoteric metals such as dissolve in caustic soda or ammonia. 1 It is believed that these parchmentizing I agents form combinations with the cellulose,

.tion pro leaving the same in a basic condition for the receptlon of the ingredients of the condensaduct. I have found that it is not necessary izing agent, fore further dipped into phenol although this may be done hetreatment. The treated fiber is which may be liquefied My method may be an pressure,

y. a 20% solution, considerable to remove the encess of p'achmentof that combined with the base can be eontrolled by mechanical means, such as ueezin of the fiber, concentration ofthe p enol so ution, etc. The material is then saturated with formaldehyde or its equivalent by exfiosing the same to formaldehyde vapors or ipping into a formaldehydesolution. The im regnated fiber is then subjected to heat,

if desired, to convert the material into intermediate condensation prodnote, after which the mineral constituents with which the fiber has been loaded maybe removed by washing, if so desired, and'the material is then further heated under pres sure to complete the reaction.

enol held by the fiber in excess Various modifications of this method may be made. For instance, after parchmentization, treatment with phenol and formaldehyde may be made simultaneously, or the cellulose may be first treated with a mixture of parchmentizing agent and phenol which are allowed to react simultaneously upon the fiber, after Wl'llCh it is treated with formal dehyde and subjected to heat and pressure,

as above.

- If desired, the cellulose may be hydrated or parchmentized treated with the formaldehyde first and then with phenol or its equivalent, after which the condensation product is formed by heat and pressure. In this, case also, I may simultaneously parchmentize and impregnate with formaldehyde by the use of a solution of formaldehyde and parchmentizingagent, which is followed by a treatment with phenol, and then the condensation product is formed by. heat and pressure.

A still further modificatlon lies in form ing a mixture of phenol, formaldehyde, and

parchmentizing agent, and treating the fiber directly with the mixture, after which the condensation product is formed by heat and pressure.

A' practical method of utilization of my invention is as follows: A sheet of paper, generally in the form of ing agent, such as a 20% solution of caustic soda containing 10 to 15% sodium chloride, then into a bath of phenol, andthen throu h hyde.

a roll, is continuouslypassed through a bath of parchmentizapplied, forming an intermediate 'condensation product which is soluble and fusible. At this point, it is sometimes desirable to remove the parchmentizing agent, 'Which isreadily done by passin the sheet through water, after which it is i lried', generally in a vacuum. The paper thus 'thoroughl. impregnated with an intermediate con ensation product may then be either rolled for shipment or out n 'directly into desired form, for instance, iscs, a number of which are assembled and subjected to further heat 4 and pressure to compact the material and to be formed limits at will, and I have produced conden-- sation products containing from 102 to over 300% of the original weight of the cellulose.

My method is extremely simple, consisting of but few easily controlled steps, requiring very little manipulation, and the various steps of my process are less sensitive to chan es in conditions, requiring less experienced operators than pr1or methods. The degree of impregnation may be very easily controlled and cheaper ingredients may be used, enablin awide variety of products K my method at less expense. Although I ave described my invention with the use of phenol and formaldehyde and paper, it is to be understood that my invention is not limited to the use of these ingredients specifically, since it is obvious that various equivalent materials 'may be used in place thereof. For instance, cresol orvarious homologues of the phenolic type ma be used in lace of phenol and the forma dehyde may replaced by triox-ymethylene, hexamethylene tetramine, or other substances having an active methylene group. M invention is not confined to the use of ce lulose but other carbohydrates, such as suganand starch, may be'substituted therefor. It is tobe understood that, by the use of the terms phenol, formaldehyde and cellulose, I do not confine myself to the specificjmaterials' described in connection with my method but include all reasonable equivalents thereof. Theterm hydrated as ap lied to cellulose is intended to include pare mentized, hydrolyzed and vulcanized material and is not limited to a cellulose which contains additional elements of water.

I claim as my invention 1. A method of forming a condensation product which consists in treating cellulose with a parchmentizing, agent, treating the cellulosic. material with a phenol. and then treating the mixture with formaldehyde to form resinous material.

2. A method of forming a condensation product which consists in simultaneously treating cellulose with a parchmentizing agent and a phenol, and then treating with formaldehydeto form resinous material.

3. A method of forming a condensation product which consists in simultaneously treating cellulose with-a parchmentizing and condensing agent and a phenol and then treating with formaldehyde to form resinous material. I

4. A method of forming a condensation product which consists in simultaneously .treating cellulose with an alkaline salt capable of parchmentizingcellulose and a phenol, and then treating with formaldehyde to form resinous material.

5. A methodof forming a condensation product which consists in simultaneously treating cellulose with an alkaline salt of an:

amphoteric metal and aphenol, and then' treating with formaldehyde to form resinous material.

product which consists in simultaneously treating'cellulose with sodium zincate and a phenol, and then treating with formaldehyde to form resinous material.

' In testimony whereof, I have hereunto 6. A method of forming a condensation subscribed my name this 18th day of September 1920.

HENRY C. P. WEBER. 

